Building elements

ABSTRACT

A building panel  20  is disclosed which is of sandwich construction having metal sheet structures  21, 22  interconnected by a core  23.  The panel  20  includes profiled edge regions  24, 25  enabling the panel to interlock with a like panel. In one form a paper covering  27  is bonded to the metal sheet structure so that panel has a surface characteristic similar to that of plasterboard. A reinforcing element  40  is also disclosed which is arranged to be connected at the join between abutting panels to improve the load bearing capability of the panel  20.

CROSS REFERENCE

This is a continuation-in-part of U.S. application Ser. No. 09/673,001 filed 6 Oct. 2000, the contents in which are herein incorporated by a cross reference.

TECHNICAL FIELD

The present invention relates to building elements and methods of building construction.

BACKGROUND

In the building industry, panels are widely used in interior walls, partitions and ceilings. Building panels are also used on external cladding, partition wall cladding and roof cladding. One of the most common type of internal paneling used is plasterboard, which traditionally is formed from a core of gypsum or anhydrite plaster, faced with two sheets of heavy paper. Plasterboard has gained widespread acceptance because it is inexpensive, relatively light weight, can be easily cut and provides a good surface finish.

However, there are significant problems with plasterboard. Traditional plasterboard panels are not self supporting and need to be fixed to a supporting frame such as a stud wall or the like. This substantially increases the cost of installation. Furthermore, plasterboard has relatively poor thermal and acoustic insulation properties as compared to block walls, and is relatively inflexible thereby making it difficult to form into complex shapes.

Various proposals have been made to address these problems. These include the development of hollow core reinforced plaster panels or prefabricated sandwich panels made form two sheets of plasterboard bonded to a paper honeycomb core. Whilst such designs are self supporting, they have limited applications and have not gained widespread acceptance.

SUMMARY OF THE INVENTION

According to one aspect, there is disclosed a building panel which includes a metal sheet substrate and a paper covering bonded to the substrate.

Throughout the specification the term “paper” includes sheet material formed from any fibrous material produced from either naturally occurring or synthetic fibres. The sheet material may be of unitary or composite construction. It also includes other types of sheet material which have characteristics, in particular surface texture, which are similar to paper.

A cladding or partition formed using the panels, can be finished to appear continuous using standard techniques used on plasterboard walls. Such techniques include plaster rendering and the use of plaster tape.

In one form, the panel is formed in continuous lengths using a laminating process to adhere the paper covering to the metal substrate. The production of panels in this way provides significant cost benefit and also has the advantage of enabling panels of indefinite length to be produced.

In one form, the panel includes longitudinal edges which are profiled. These profiles may be incorporated to allow the panel to be interconnected with like panels, or associated componentry such as fixing rails, edge trim or the like. The profiled edges may also be designed to allow the panel to interconnect with a traditional plasterboard panel so that the panel can easily be used in conjunction with these traditional plasterboard panels. In addition, the panel may be profiled to enhance it's load bearing characteristics. These strengthening profiles may be included at the longitudinal edges, or could be incorporated mid span in the form or ribs or corrugations or similar structure. The profiles may be formed in the panel using any known technique such as roll forming, folding or the like. However in a particular form, the panels are roll formed to the desired profile. In this way this forming step can be easily include as an extension to the laminating process.

Any appropriate sheet metal may be used as the substrate, such as steel, aluminium, tin or the like. In general construction, galvanised steel has wide application as the metal substrate as it is relatively inexpensive, has good structural properties and is corrosive resistant. The gauge of the metal substrate may be chosen depending on the required structural properties of the panel. However it is envisaged that the gauge will be between 0.3 to 1 mm in the most applications. Metal falling within this range of thicknesses can easily be cut thereby enabling services to be easily installed in the panel on the site.

In one form, the panel is bonded directly to the metal surface. In one form, a reactive hot melt adhesive is used to bond the paper to the metal substrate. An advantage of using a reactive hot melt adhesive is that it provides high bond strength including high initial adhesive and cohesive strength which makes it ideal for laminating the paper directly onto the bare metal substrate. The ability to bond the paper directly onto a metal substrate again provides significant cost benefit in that it avoids the need for pre-treatment of the metal such as the application of a primer coat to the metal surface. However, it is to be appreciated that the intermediate layers such as paint or waterproof coatings may be included between the metal substrate and the paper covering if required.

In one form, the adhesive is applied by a roller to the metal surface, as this gives good even coverage of the adhesive across the substrate surface which is important for providing an even surface finish on the panel.

The building panel has widespread application and can be used instead of, or in conjunction with, traditional paneling such as plasterboard. For example, the paneling of the invention may be used as a fascia, a ceiling panel or the like. In addition it may be used in conjunction with a traditional plasterboard partition (such as a wall). For example, the panel may be included in a section of a plasterboard wall where a complex surface, such as a curved wall, is required which could not be formed using conventional plasterboard.

The building panel may also incorporate additional layers to improve its structural properties. For example, the panel may include additional insulating or thermal layers bonded to the metal substrate on the opposite surface to the paper covering. Again these additional layers may be bonded using any known technique but are preferably applied using a laminating process so as to be easily incorporated in the overall forming process of the panel.

In a particular form, the building panel is incorporated as part of an integrated structural or composite panel. In this arrangement, the composite panel includes spaced facing sheets which are interconnected by a core and wherein at least one of the sheets includes a building panel as described above with the paper covering forming an outer surface of the composite panel.

A composite panel according to this form has widespread application for use as interior walls or partitions or as combination external/internal wall. The composite panel is self supporting, is able to be configured to be load bearing and can incorporate profiled edge regions to enable the panel to be interlocked with adjacent panels.

In one form, both the filing sheets of the panel are formed at least partially from a metal sheet. If only one side of the panel is to be an exposed interior wall, then only the exposed face need include the covering; the other face may remain bare metal. If both sides are to be viewed then both faces can include the paper covering. Alternatively, if required, different surface finishes may be used. For example, one surface may include a plastic or similar water impermeable covering for use in a bathroom or the like while the other face may include the paper covering. If required, one face may include a decorative surface such as a timber veneer or the like. Alternatively one face may form an external surface and may be profiled or designed to be coated with an appropriate top coat such as a render or the like.

In a further aspect, a composite panel is disclosed for use as exterior cladding, the panel being of sandwich construction comprising a core, an exterior facing sheet and an interior facing sheet, the facing sheets being fixed to respective ones of the opposite major surfaces of the core wherein the interior facing sheet has a metal substrate and a paper coating bonded to the substrate.

In one form, the exterior facing sheet comprises a steel sheet substrate having a corrosion resistant metal coating applied thereto.

In one form, the exterior facing sheet has a cross-sectional profile displaying crests and troughs which are displaced from a centre plane of the sheet. The profiled exterior facing sheet may be in the form the corrugations, ribs, pleats or the like. Further, the crests and troughs may be smoothly curved throughout or the profile may comprise straight portions meeting at relatively abrupt angles, or a combination of both these possibilities.

An advantage of using metal sheet as part of the composite panel is that the longitudinal edges can be formed so as to enable the panel to connect with adjacent panels thereby facilitating the construction of a partition, using the structural panels. The profile of the longitudinal edges of the composite panel may be such that no additional fasteners are required. Alternatively, the edge profiles may be designed solely to align the adjacent panels and mechanical fasteners such as rivets, screws or inserts are used to fasten the panels together.

In one form, the panels are installed using top and bottom rails. The rails may have a simple C-shaped cross section. In this arrangement, the depth of the rails, the distance they are spaced apart, and the height of the panel is related so that the panels may be easily installed by merely locating the upper end of the panel into the top rail and then swinging the bottom end of the panel into alignment with the bottom rail and then dropping the panel down into the bottom rail. The panel is then captured between the top and bottom rails and may be secured in place by fasteners, such as rivets or self tapping screws or the like. It is to be appreciated that other fastening arrangements may be used. For example the rails may be specially formed so that they interlock with the panels without the need for separate fasteners.

In an alternate form, the panel is mounted to a frame, such as a portal frame.

In one form, one of the edge regions of the exterior facing sheet projects beyond the edge region of the panel to form a tail portion, and wherein when the panel is interconnected with another panel at that edge region, the tail portion overlaps the exterior facing sheet of the other panel.

In another aspect, there is disclosed a roofing panel of sandwich construction comprising a core, an exterior facing sheet, and an interior facing sheet, the exterior facing sheets being fixed to respective ones of opposite major surfaces of the core, wherein the interior facing sheet has a sheet metal substrate and a paper coating bonded to the substrate, and wherein the exterior facing sheet comprises a sheet steel substrate that incorporates a corrosion resistant metal coating.

In one form, the exterior facing sheet of the roofing panel has an outer surface that is pre-painted. Further, in one form, the exterior facing sheet has a cross-sectional profile that displays crests and troughs displaced from a centre plane of the sheet.

The core of the composite panel may be of any suitable form depending on its application or requirements. In particular, the core may be of solid construction of may be of open form including interconnecting webs to thereby form cavities within the core. These cavities may be used to reduce the weight of the integrated panel or to provide passage for services such as wiring and the like. The core may be formed of a polymeric composition such as polystyrene or polyurethane, or may be formed of other settable material such as cementitious based materials. In one form, the core is chosen to have fire retardant properties.

In one form, the edge profiles are shaped to form a slip joint at the interlock between the adjacent panels. In this arrangement, one edge profile forms the male component of the slip joint where as the edge profile of the other panel forms a complimentary female component of the joint. In one form, the panels are arranged to interlock in a manner where one panel is drawn into engagement with another panel so as to facilitate proper engagement of the panels and to resist inadvertent separation.

In another form, the edge profiles are specifically designed to form a load bearing member at the interlock between adjacent panels. In one form, the interlock is still by virtue of a male/female coupling but the edge profiles are shaped to form a part box section. This section has inherent strength and also is convenient for use in the passage of cabling or other services. Moreover, the male coupling may be arranged to be drawn into tight engagement with the female couple so that the overlapping structure of the male and female connection acts in unison thereby increasing the load bearing capability of the panels.

In one form, the composite panel is designed to be able to receive a structural member between its facing sheets. The structural member improves the load bearing capability of the panel and preferably comprises a metal beam.

In one form, the edge profiles are designed to be able to receive the structural member so that the member is contained within the connection between the adjacent panels and is fully concealed. In this way, a wall formed from the panels may be continuous across the join which contains the reinforcing member.

In a further arrangement, the edge profiles are formed separate to the panel and are arranged to be located over, and secured to, the edge margins of the panels which are typically unformed. This arrangement enables use of a composite panel with straight edges. Alternatively, the separate edge profiles may be used as an accessory to the building system incorporating the composite panels with the profiled edges. For example, the edge profiles may be used when it is required to cut the composite panel or when the composite panel is required to interfit with conventional panels or other building members.

In a further aspect, there is disclosed an elongate building element formed as a hollow section and having spaced apart first and second ends, opposite side surfaces and opposite end surfaces extending between the ends, the element being formed from first and second parts, the parts extending between the first and second ends and interfitting in a manner that allows the size of the hollow section to be varied.

In one form, each part is channel shaped having a web and opposing flanges, wherein on interfitting of the parts, the flanges of one part is lapped with the flanges of the other part so as to form the opposite side surfaces, and the webs of the parts form the opposite end surfaces.

In one form, at least one of the webs is profiled so as to form a connecting element which extends along that web.

In one form, the elongate building element is used as an internal stud and may be used in conjunction with the composite building panel as disclosed above. In one form, at least one of the parts is formed from a metal sheet substrate and a paper covering bonded to the substrate. In one form, both parts are so formed.

In a further aspect, a building system which has enhanced load bearing capabilities is disclosed.

According to this aspect, a building system comprises a building panel and a reinforcing element, the building panel having spaced sheet structures interconnected by a core, said sheet structures defining opposite major surfaces of said panel and wherein the element is locatable between the planes of said major surfaces so as to form in use, a concealed reinforcing member which is operative to improve the load bearing characteristics of said panel.

In one form, the sheet structures are formed of metal and at least one of the sheet structures may incorporate a paper covering as previous disclosed. Alternatively, the metal sheet structures may be fully exposed such as if a stainless steel surface is required, or other finishes or composite materials may be used.

The advantage of this system is that it provides a building panel with enhanced load bearing properties as compared to simple sandwich panels. Further, fully concealing the reinforcing member enables continuous smooth surfaces on both sides of the panels to be obtained.

A panel in accordance with this aspect of the invention is suitable for use both as wall panels, ceiling floor paneling or exterior wall or roof cladding.

In one form, the sheet structure includes longitudinal edge regions which are profiled to enable the panels to be connected in abutting relationship with a like panel in edge to edge relationship and the reinforcing member is locatable within the join formed at the abutting panels.

In one form, the panel is arranged to connect with a like panel at the longitudinal edge regions. The longitudinal edge regions may interlock with the reinforcing element. This arrangement has the advantage that it further increases the load bearing capability of the panel as the reinforcing member and the profiled longitudinal edge regions can work together.

A method of constructing a partition is also disclosed having an exterior and interior surface, the method comprising the steps of:

-   -   providing a plurality of panels, each panel being of sandwich         construction and comprising a core, an exterior facing sheet,         and an interior facing sheet, the facing sheets being fixed to         respective ones of opposite major surfaces of the core, the         interior facing sheet having a metal sheet substrate and a paper         covering bonded to the substrate;     -   interconnecting the panels so that the exterior and interior         major surfaces of the interconnected panels are aligned and in         substantially abutting relationship; and     -   applying finishing techniques to both the interior and exterior         major surfaces of the interconnected panels to form continuous         interior and exterior surfaces across the interconnected panel.

BRIEF DESCRIPTION OF THE DRAWINGS

It is convenient to hereinafter describe embodiments of the present invention with reference to the accompanying drawings. It is to be appreciated however that the particularity of the drawings and the related description is to be understood as not limited the preceding broad description of the invention.

In the drawings:

FIG. 1 is a perspective view of a panel;

FIG. 1A is a detailed view to an enlarged scale illustrating the construction of the panel of FIG. 1;

FIG. 2 is a perspective view illustrating the panel in FIG. 1 used as a ceiling panel when in position;

FIG. 3 is a perspective view of a composite panel

FIG. 3A is a detailed view to an enlarged scale illustrating the construction of the panel of FIG. 3;

FIG. 4 is an exploded perspective view illustrating the connection of the panel of FIG. 3 with another panel;

FIG. 5 is a cross sectional view of the connection of the panel of FIG. 3 with another panel;

FIG. 6 is a perspective view illustrating the connection of a variation of the panel of FIG. 3 with another panel and including an intermediate reinforcing member;

FIG. 7 illustrates a variation of the panel of FIG. 3 and its connection with another panel;

FIG. 8 is a partial perspective view illustrating the connection of an end trim component to the panel of FIG. 7;

FIGS. 9A and 9B are schematic side views showing installation of the panel into top and bottom rails;

FIG. 10 is a perspective view illustrating the connection of a variation of the panel of FIG. 3 with another panel and including an intermediate reinforcing member;

FIG. 11 illustrates a variation of the panel of FIG. 3 incorporating separately formed longitudinal edge profiles;

FIG. 12 is a partial perspective view illustrating the panel of FIG. 10 when used as a flooring system;

FIG. 13 is a line diagram of a laminating process for use in the production of a building panel;

FIG. 14 is a schematic perspective view of the parts of a stud member;

FIG. 15 shows the stud member of FIG. 14 when in an assembled form;

FIG. 16 is a partial perspective view of a roofing panel;

FIG. 17 is a schematic view of the roofing panel of FIG. 16 being installed on a frame; and

FIG. 18 is a schematic view of a house constructed using various panel elements.

The panel 10 is of composite material and formed from a laminating process which forms the panel in continuous lengths. The panel may be of any desired width, although if made from one sheet, the width will be limited by the width of the feed stock. In one form, the panel is formed in standard widths of 120 mm, 900 mm, 600 mm and 300 mm.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a building panel 10 which is generally planar and includes opposite major surfaces 11 and 12 interconnected by edge regions 13 and 14.

The panel includes a metal substrate 15 and a paper covering 16 which is bonded to the substrate 15 by a reactive hot melt adhesive 17. The covering 16 constitutes a heavy plasterboard paper so that the outer face 11 of the panel has the same general appearance and surface characteristics of a plasterboard panel. In the illustrated form, the substrate 15 is formed of galvanised steel thereby enabling the inner surface 12, which in use is concealed, to remain exposed due to its corrosive resistant properties.

The edge portions 13 and 14 of the panel are profiled so as to enable the panel 10 to be connected at these edge regions to another panel. In the illustrated form, the profiles on the edge regions 13 and 14 are formed by roll forming the metal substrate 13. The edge regions 13 and 14 are formed with one edge portion 13 forming a female coupling which is adapted to receive and contain the other edge region 14 which is formed as a male coupling. With this arrangement, the male edge region 14 located in and is retained within a seat 18 formed within the female edge region 13 of a like panel so that the adjacent panels can be interconnected along their edge regions.

It is to be appreciated that the profiles formed in the edge regions 13 and 14 may take different forms as will be appreciated to those skilled in the art of roll forming techniques. Specifically, the profiles can be matched to suit the particular requirements of the panel and the mode of connection required between adjacent panels. For instance, the profiles may be designed such as those illustrated, to not require the addition of any mechanical fasteners to interconnect like panels together. Alternatively the edge regions could be formed so as to provide formations to receive specific mechanical fasteners such as rivets or screws or the like.

FIG. 2 illustrates the panel 10 in place as part of a ceiling with the panel 10 aligned, and fixed to, the underside of parallel roof battens 60. In the illustrated form, the battens incorporate clips which are adapted to engage and hold the edge regions 13 and 14 of the panels. In this arrangement, the ceiling panels are installed progressively across the batten. A first panel 10 ^(i) is installed and fastened to the clips 61. A second panel 10 ^(ii) is then installed by locating the male edge region 14 ii within the female edge region 13 ^(i) of the affixed panel 10 ^(i) whilst the panel 10 ^(ii) is inclined relative to the fixed panel 10 ^(i). Once located in place, the panel 10 ^(ii) is then swung up into alignment with the panel 10 ^(i) wherein its female edge region 13 ^(i) engages with associated clips 61 attached to the battens. The process then continues until all the panels are in place.

With this arrangement, the fixed panels 10 have respective outer faces which incorporate the plasterboard paper covering and thereby have a general appearance of plasterboard. If required, edge trim (not shown) can be inserted between the adjacent panels. Typically the panels would include a bead or similar protrusion which locates within an associated groove (not shown) formed in the edge regions 13 and 14 of the respective panels. Alternatively, the join between the panels could be concealed so that the ceiling surface is continuous using standard finishing techniques such as plaster rendering or the like.

FIG. 3 illustrates a composite building panel 20. The panel 20 is of sandwich construction incorporating first and second facing sheets 21 and 22 respectively, which are interconnected by a core 23. The panel 20 further includes edge regions 24 and 25 which are profiled to enable the panel 20 to be interconnected to another panel.

As best illustrated in FIG. 3A, each of the facing sheets 21 and 22 incorporate a structure which is similar to the panel 10 illustrated above. Specifically the sheets 21 and 22 incorporate a metal sheet substrate 26 which includes a covering 27 formed from heavy plasterboard paper which is bonded to an outer surface 28 of the metal substrate 26 by a reactive hot melt adhesive 29. Similarly, an inner face 30 of the metal substrate 26 is bonded to the core 23 by a similar adhesive 31. The longitudinal edge regions 24 and 25 are profiled by roll forming the respective edge regions of the metal substrates 26 of the respective sheets 22 and 21.

The core 23 of the panel is illustrated as a foam block. Typically the foam is a polymer foam such as polystyrene or polyurethane. However it is to be appreciated that the core may be formed of any suitable structure depending on the application of the panel 20. For example, the core may be formed from a composite construction and/or may include cavities or channels if desired.

In a similar manner to the earlier described embodiment, the panel 20 is formed from a laminating process. Typically the sheets 21 and 22 are formed in a first laminating process. The sheets then form part of a second laminating process where they are bonded to the core. If desired, additional layers can be bonded to the panels to further improve the structural properties of the panel 20. For example additional layers may be incorporated to further increase the thermal or acoustic insulation properties of the panel. By virtue of the laminating process, the panels 20 are formed in continuous lengths and are typically formed in a range of standard widths such as 120 mm, 900 mm, 600 mm and 300 mm.

The panel 20 has the general appearance and surface characteristics of plasterboard by virtue of the heavy paper covering 27. However because of its sandwich construction and sheet metal substrate, the panel 20 is lightweight, yet is self supporting and capable of acting as a load bearing member.

The edge regions 24 and 25 of the panel 20 are roll formed to include a longitudinally extending projection 32 and recess 33 which are located intermediate the opposite outer surfaces 38 and 39 of the panel 20. In the illustrated form, at edge region 24, the projection 32 is formed from roll forming the edge of the structure 21 whereas the recess is formed from roll forming the edge region of the structure 22. An abutment face 34 is located between the face 38 and projection 32 and a similar abutment face 35 is formed between the recess 33 and the face 39.

Both the projection 32 and the recess 33 are shaped to be complementary such that the projection 32 is able to be received within the recess 33 of another panel. To facilitate interconnection of adjacent panels, both the projections and the recesses include tapered surfaces to provide adequate lead in.

The other longitudinal edge region 25 of the panel 20 includes a similar edge profile and includes both a recess 32 and a projection 33, with the exception that the projection is formed from roll forming the edge of the sheet structure 22 whereas the recess 33 is formed from roll forming the edge region 21.

The panel 20 is arranged to be self supporting and typically arranged to be installed between top and bottom rails (62 and 63) which are formed as C-shaped channels or the like. FIGS. 9A and 9B illustrate the installation of the panel 20 between the rails 62 and 63. The panels are easily installed by merely locating the upper end 51 of the panel into the top rail 62 and then swinging the bottom end 52 into alignment with the bottom rail 63 and then dropping the bottom panel 20 into the bottom rail. The relationship of the distance between the panels to the height of the panel is such that the panel remains captured between the top and bottom rails as best illustrated in FIG. 9B. Once in this position, the panels can then be interlocked with a like panel as will be described in more details below. Once fully in position the panels are then secured in place to the rails merely by the use of fasteners, such as rivets or self tapping screws or the like.

FIGS. 4 and 5 illustrate the connection of the panel with another panel. For ease of identification, one panel is designated 20 ^(i) whereas the other panel is designated 20 ^(ii). Other features of the panels are distinguished in a similar manner.

As best illustrated in FIG. 5, the edge regions 24 ^(i) and 25 ^(ii) enable two panels 20 ^(i) and 20 ^(ii) to be connected in edge to edge relationship with the respective projections and recesses of the edge region 24 ^(i) engaging with the respective projections and recesses of the edge region 25 ^(ii) of the adjacent panel 20 ^(ii). Furthermore, the abutment surfaces 34 ^(i) and 35 ^(ii) engage so as to form a simple linear join 36 between the abutting panels 20 ^(i) and 20 ^(ii).

In the illustrated form, both the longitudinal edge regions 24 and 25 of the panel is slightly waisted to form a recessed portion 37 in the outer surface of both the facing sheets 21 and 22. This recess is designed to enable the join 36 between adjacent panels to be easily covered over by plaster tape or plaster rendering which will be applied within this recess and create a flush surface across the join.

The profile of the edge regions 24 and 25 also enables the panel 20 to be easily used in conjunction with standard plasterboard panels. Specifically, the abutment surfaces 34 and 35 provide a space to enable a plasterboard panel to be located in abutting relationship with the panel 20. The abutment surfaces 34 and 35 are dimensioned to be slightly larger than a standard plasterboard panel which is typically 10 mm or 13 mm, so as to provide adequate clearance for the plasterboard panel to be located outside the projection 21 and the recess 33 so that the plasterboard surface can be flush with the respective faces 38 and 39 of the panel 20.

The coupling arrangement to join adjacent panels using the interfitting projections and recesses 32 and 33 provide an area of load bearing strength at the engaged edge regions. This improves the load bearing characteristics of the wall formed by the adjacent panels. In most applications, the interconnection of the panels gives the wall sufficient load bearing characteristics. If, however, additional load bearing strength is required in the constructed wall using the panels 20, a metal reinforcing member 40 may be incorporated at the connection. Once such example is illustrated in FIG. 6 where the reinforcing member is formed from roll formed metal sheet 41 and incorporates oppositely disposed channels 42 and 43 which are arranged to interfit between the engaging projections and recesses (32 and 34) of the adjacent panels 20 ^(i) and 20 ^(ii). The member 40 substantially improves the load bearing characteristics of the wall as, by virtue of its configuration and its engagement with the adjacent panels, it is able to accommodate substantial compressive loading.

FIG. 7 illustrates a variation of the coupling arranging between adjacent panels 20 ^(i) and 20 ^(ii). In this arrangement both the longitudinal edge regions 24 and 25 incorporate a pair of recesses 33. As illustrated in FIG. 7 in connecting the panel 20 ^(i) to the like panel 20 ^(ii), the recesses 33 ^(i), 33 ^(ii) of the respective panels are arranged to be aligned and inserts 44 are located within the cavity formed between the aligned recesses to couple the panels together.

The inserts may be of any suitable form and may include a continuous strip 45 which extends over the majority of the length of the connected panels, or may be in the form of smaller wedges 46 which extends over only a portion of the length of the panels.

FIG. 8 illustrates a specially formed edge strip 50 which is arranged to be coupled to the longitudinal edge region 24 or 25 of the panel 20. The edge strip 50 may be solely as a decorative end strip or may have a functional purpose such as to form part of a door frame assembly as in the illustrated embodiment where the strip 50 is configured to form a doorjamb.

FIGS. 14 and 15 illustrates a building element 70 that is engagable with the longitudinal edge region 24 or 25 of the panel in a similar manner to the edge strip 50. The element 70 is formed from a first and second part each of which are typically formed from profiling sheet metal that incorporates a paper covering. Each part 71 and 72 is formed generally as a channel section having a web 73, 74 and respective flanges 75, 76, 78 and 79. As best illustrated in FIG. 14, the parts 71 and 72 are designed to be brought together so that the flanges of the parts overlap so that the element 70 forms a hollow section. Typically, the overlapping flanges can be secured in place through the use of fasteners 78 which are typically rivets or screws. In this way, the overlapping flanges form first and second sides 79 and 80 with the webs 73, 74 forming the opposite end edges of the element which interconnect the sides 79, 80.

The element 70 is designed as a stud member and locates between adjacent panels 20. To facilitate the connection of the element 70 to the panels 70, the end surfaces 73, 74 of the element 70 include connecting elements in the form of recesses 81 and projections 82 that are designed to interconnect with the connecting element 32, 33 of the panel 20.

By having the parts 71, 72 of the element 70 being formed with a paper covering and using a connection system which complements the connection system used on the panel 20 it is possible to interfit the element 70 between adjacent panels whilst maintaining a continuous surface. The element 70 can be used as a structural member and/or to handle services in a partition formed by interconnection of the panels 20.

A further feature of the element 70 is that as it is formed in separate parts, it is possible to change the amount of overlap between the flanges thereby varying the size of the hollow section. This arrangement can have particular advantage when installing a partition with the element 70 providing some adjustment in the width of the partition.

FIG. 10 illustrates a further variation of the panel 20. This panel includes many similar features to the earlier embodiments and accordingly like reference numerals have been given to like features. In a similar arrangement to the previous embodiments, the panel 20 includes longitudinal edge regions 24, 25 which are profiled to enable the panel 20 to interlock with a like panel. A reinforcing member 40 is also arranged to interfit at the join between adjacent panels.

In the illustrated form, the longitudinal edge region 24 provides a pair of recesses or female couplings 33 whereas the edge regions 25 provide a pair of male couplings or projections 32. It is to be appreciated that if desired, each edge region could include both a male and female coupling similar to that illustrated in FIG. 3.

In the embodiment of FIG. 10, the profiles have been specifically designed to give the panel enhanced load bearing characteristics at it join with an adjacent panel. The male and female couplings are shaped to provide generally a part box section which interlocks through resistant action of the couplings. In particular the male coupling is drawn into engagement with the female coupling by this resilient action. This arrangement has the advantage that the box section provides good load bearing characteristics and the interlocking action draws the interlocking members together. This inhibits inadvertent separation of the members and also enables the interlocking panels to act as a single unit thereby enhancing the panels overall load bearing capabilities at this connection.

The male coupling 32 includes opposite walls 53 and 54 which are interconnected by a base portion 55. To provide the resilient action, the walls 53 and 54 are not linear but rather include outwardly extending crests 56 intermediate the ends of the respective walls 53, 54. The female coupling 33 incorporates a complementary shaped recess. Specifically, the female coupling 33 incorporates opposite walls 57, 58 which are interconnected by base portion 59 and which incorporate re-entrant portions 64 on their inner surface. In use, on interconnecting the panels together the male and female couplings are caused to flex through engagement of the male coupling walls 53, 54 with the female coupling walls 57, 58. The flexing continues until the crests 56 begin to align with the re-entrant surfaces 64 whereafter the couplings begin to return to their natural state as the crests move into alignment with the re-entrant surfaces 64. Once in alignment, the resilience of the couplings inhibits the release of the two interconnected members.

The positive or resilient fit between the male and female coupling occurs whether or not the reinforcing member 40 is incorporated. The profile of the reinforcing member 40 has inner surfaces 65 which matches that of the female couplings 33 and an outer surface 66 which matches that of the male coupling 32. As a result, the reinforcing member 40 is able to fit into connection with the female couplings 33 ^(i) of a first panel 20 ^(i). Once in place, the male couplings 32 ^(ii) of the like panel 20 ^(ii) is then able to locate into engagement with the inner surface 65 of the connected reinforcing member 40.

FIG. 1 illustrates a similar view to that illustrated in FIG. 10 except that the edge profiles 24,25 are formed separately to the panel 20. In this arrangement, the edge profiles 67, 68 are similar to the edge strip 50 are formed from a folded metal sheet and are secured to the edge margins of the panels using any suitable fastening arrangements such as by screw, adhesive or the like. These edge profiles 67, 68 enable the system to be used with a panel 20 having a straight edge and may be used when it is required to cut the structural panel or when the structural panel is required to interfit with conventional panels or other building materials.

The composite panel 20 incorporating the profiled edges and the internal reinforcing member 40 may be advantageously used in many aspects of building constructions including in interior as well as exterior wall structures, or in flooring or ceiling systems. Further, the choice of the surface materials used to form the outer faces 38, 39 of the panel will depend on the application of the panel. For example, if the panel is to be used as an internal partition wall, then the paper covering may be laminated to the metal substrate as described earlier so that the panel has a surface characteristic which is similar to that of plasterboard. Alternatively, the outer face of the panel may be exposed metal, such as stainless steel, which is suitable for use in operating theatres or the like. In this example, to reduce material cost, the stainless steel may be applied as a laminate to the metal substrate of the panel 20 or alternatively the substrate may be formed from solid stainless steel. It is to be appreciated that other surface configurations could be used as will be appreciated by those skilled in the art.

FIG. 12 illustrates a further variation of the panel when used as part of a flooring system. In this arrangement the reinforcing member 40 acts as an internal bearer thereby providing the required loading characteristics for the flooring system. In this arrangement the upper face 38 incorporates a timber veneer so as to give the impression of a timber floor.

FIG. 16 shows a further variation of the panel when used for roofing. This arrangement of the roofing panel 85 includes an exterior facing sheet 86 and an interior facing sheet 87. The facing sheets 86, 87 are bonded to a core 88. The interior facing sheet 87 is formed from the sheet metal substrate having the paper covering as disclosed in the earlier panel arrangements. In contrast, the outer panel 86 is made from metal and typically from a galvanised sheet steel that includes a pre-painted coating. Furthermore, whilst the exterior panel 86 can be substantially flat, in the embodiment shown, it is profiled as is typical in roof cladding. In the illustrated form, the profile is the roofing panel 86 is corrugated.

In the illustration shown in FIG. 16, two roofing panels 85, 85 ^(i) are shown. These panels are interconnected along edge margins 89 and 90 ^(i). Further edge regions 89, 90 are profiled so as to provide a connection detail which in the illustrated form, comprise an interfitting projection and recess (91 and 92 ^(i)). In addition, the roofing panel 85 is arranged so that an edge portion 93 of the exterior facing sheet projects beyond the edge region 89. In this way, this edge region 93 forms a tail portion which is designed to overlap with the exterior sheet 86 ^(i) of the other panel 85 ^(i).

An advantage of the roofing panel 85 is that once installed, the interior facing sheet 87 is caused to move into abutment with the interior facing sheet 87 ^(i) of its adjacent connected panel 85 ^(i). As the material facing sheets 87 ^(i) are paper coated, a finished interior surface can be easily formed by using standard finishing techniques in a similar manner as described above in conjunction with the panel 20.

FIG. 17 illustrates the installation of the roofing panel 85 on a portal frame 150. In this arrangement, the portal frame 150 includes top and bottom members 151, 152 and rafters 153. Purlins may also be provided with extend between adjacent rafters 153. The roofing panels are located onto the portal frame 150 in a manner which is similar to existing roofing cladding. Individually they are fixed to the frame by mechanical fasteners. The construction is particularly suited for raked ceilings where the interior surface 87 of the roofing will be exposed.

FIG. 13 illustrates a line diagram of a laminating process used to bond the paper covering to the metal substrate for use in the building panel of the invention.

In this process, the metal feed stock 26 which is typically galvanised steel but may be any other sheet metal, is fed from an uncoiler 101 into the process line 100. The sheet metal is then correctly positioned by running through an edge guide 102 and then subsequently through a straightener 103. The sheet metal then passes through a cleaning and heating unit to remove any debris on the metal surface and to bring the temperature up to a predetermined level. The exact temperature range used is dependent on the characteristics of the adhesive being applied but is typically in the range of 20 to 50° C. The sheet metal then passes through to an adhesive coater 105 which incorporates a roller 106 which comes into contact with the upper surface 28 of metal substrate 26 so as to apply a thin film to the metal sheet. The adhesive is a reactive hot melt polyurethane and is typically applied at a temperature in the range of typically 110 to 140° C. with a coating being applied to the metal surface in the order of 10-20 mircons in thickness.

After the adhesive has been applied, the metal sheet 26 then passes through a humidifier 107 which further conditions the adhesive coating on the metal surface 28. The sheet then passes to a laminator 108 where the paper 27 which is stored in a coil 109 is applied under tension to the surface 28 of the metal 26. The laminated product is then fed to a recoiler wherein it is stored in rolls ready for transporting (as illustrated) or to a further production station. The station further processes the metal panel and may include a roll forming station to form the edge profiles, a sheering station to form the panel into sheet form or to slit the metal panel so as to alter the panel so as to alter the panel width. To make the integrated composite building panel 20, the laminated metal sheet is fed to a separate laminating process to form the panel 20 with its sandwich construction.

FIG. 18 shows a schematic view of a house construction incorporating the above panels. Specifically, the construction (generally designated 500) includes the use of the panels 20 as external cladding. In this arrangement, one of the facing sheets 21 is designed for exterior use. This exterior facing sheet may be sheet metal (such as galvanised steel) or could be formed from other material that can cater for external use such as cement fibre or the like. The interior face 22 of the panel 20 include the paper coated metal substrate as described above.

In the illustrated form, the panels 20 are installed onto a portal frame 150. In an alternative arrangement however the frame could be formed at least partially within the cladding by the use of the reinforcing member 40 described above, or the stud member 70. Further, both the internal and external surfaces of the cladding 20 can be finished to form continuous surfaces using conventional finishing techniques. For example, the internal surfaces could be formed through the use of plaster rendering and plaster tape whilst the external surface may be coated with a render.

In addition, roofing panels 85 are installed to form the roof cladding and also to form the basis of an interior lining for the roof void 501. In addition ceiling panels 10 can be used to create ceilings between the various levels of the construction. Finally, flooring panel 90 can also be used. The flooring panel again take the basic structure of the panels 20 being a sandwich construction with the metal facing sheets. In an alternative arrangement where the flooring panels are used in intermediate levels of the building, a lower surface of the flooring panel may be paper coated so that it can be used in place of the ceiling panels 10.

Finally it is to be understood that modifications and or additions may be made to the parts as previously described without departing from the spirit or ambit of the invention. 

1. A composite building panel for use as exterior cladding, the panel being of sandwich construction comprising a core, an exterior facing sheet and an interior facing sheet, the facing sheets being fixed to respective ones of the opposite major surfaces of the core, wherein the interior facing sheet has a metal substrate and a paper coating bonded to the substrate.
 2. A building panel according to claim 1, wherein the exterior facing sheet comprises a steel sheet substrate having a corrosion resistant metal coating applied thereto.
 3. A building panel according to claim 1, wherein the exterior facing sheet has a cross-sectional profile displaying crests and troughs which are displaced from a centre plane of the sheet.
 4. A building panel according to claim 1, wherein at least one of the facing sheets includes opposite edges which are shaped to form at least part of the edge regions of the panel, each edge region being formed to include a connecting element which extends along that edge region and which allows for interconnection of the panel with another panel.
 5. A building panel according to claim 4, wherein one of the edge regions of the exterior facing sheet projects beyond the edge region of the panel to form a tail portion, and wherein when the panel is interconnected with another panel at that edge region, the tail portion overlaps the exterior facing sheet of the other panel.
 6. A building panel according to claim 4, wherein the edge regions are formed so that when the panel is interconnected with another panel, the exterior and interior facing sheets of interconnected panels are aligned and in substantially abutting relationship to enable a continuous surface to be obtained on both the exterior and the interior of the panel on the application of conventional finishing techniques to the facing sheets of the interconnected panels.
 7. A building panel according to claim 6, wherein the conventional finishing technique for the exterior facing sheet includes rendering, painting, or spraying a surface coating to that facing sheet.
 8. A roofing panel of sandwich construction comprising a core, an exterior facing sheet, and an interior facing sheet, the facing sheets being fixed to respective ones of the opposite major surfaces of the core, wherein the interior facing sheet has a sheet metal substrate and a paper coating bonded to the substrate, and wherein the exterior facing sheet, comprises a sheet steel substrate that incorporates a corrosion resistant metal coating.
 9. A roofing panel according to claim 8, wherein the exterior facing sheet has an outer surface that is pre-painted.
 10. A roofing panel according to claim 8, wherein the exterior facing sheet has a cross-sectional profile that displays crests and troughs displaced from a centre plane of the sheet.
 11. An elongate building element formed as a hollow section and having spaced apart first and second ends, opposite side surfaces and opposite end surfaces extending between the ends, the element being formed from first and second parts, the parts extending between the first and second ends and interfitting in a manner that allows the size of the hollow section to be varied.
 12. An elongate building element according to claim 11, wherein each part is channel shaped having a web and opposing flanges, wherein on interfitting of the parts, the flanges of one part is lapped with the flanges of the other part so as to form the opposite side surfaces, and the webs of the parts form the opposite end surfaces.
 13. An elongate building element according to claim 11, wherein at least one of the webs is profiled so as to form a connecting element which extends along that web.
 14. An elongate building element according to claim 11, wherein at least one of the parts is formed from a metal sheet substrate and a paper covering bonded to the substrate.
 15. A method of constructing a partition having an exterior and interior surface, the method comprising the steps of: providing a plurality of panels, each panel being of sandwich construction and comprising a core, an exterior facing sheet, and an interior facing sheet, the facing sheets being fixed to respective ones of opposite major surfaces of the core, the interior facing sheet having a metal sheet substrate and a paper covering bonded to the substrate: interconnecting the panels so that the exterior and interior major surfaces of the interconnected panels are aligned and in substantially abutting relationship; and applying finishing techniques to both the interior and exterior major surfaces of the interconnected panels to form continuous interior and exterior surfaces across the interconnected panels. 